Hybrid impact tool with two-speed transmission

ABSTRACT

A power tool that includes a housing, a motor, a planetary transmission, a first bearing and a second bearing. The motor is disposed in the housing and includes an output shaft. The planetary transmission has a sun gear, a plurality of first planet gears, a first ring gear and a carrier. The sun gear is driven by the output shaft. The first planet gears are driven by the sun gear and have teeth that are meshingly engaged to teeth of the first ring gear. The carrier includes a rear carrier plate and a front carrier plate between which the first and second planet gears are received. The rear carrier plate includes a first bearing aperture. The first bearing is received in the first bearing aperture and is configured to support the output shaft. The second bearing is received onto the rear carrier plate to support the carrier relative to the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/289,780 filed Dec. 23, 2009 and U.S. ProvisionalPatent Application No. 61/290,759 filed Dec. 29, 2009. The disclosuresof each of these applications are incorporated by reference as if fullyset forth in detail herein.

Notice: This is a reissue application of U.S. Pat. No. 8,460,153.

INTRODUCTION

The present invention generally relates to a hybrid impact tool with atwo-speed transmission.

Rotary impact tools are known to be capable of producing relatively highoutput torque and as such, can be suited in some instances for drivingscrews and other threaded fasteners. One drawback associated withconventional rotary impact tools concerns their relatively slowfastening speed when a threaded fastener is subject to a prevailingtorque (i.e., a not insubstantial amount of torque is required to drivethe fastener into a workpiece before the head of the fastener is abuttedagainst the workpiece). Examples of such applications include drivinglarge screws, such as lag screws, into a wood workpiece. In suchapplications, it is not uncommon for a rotary impact tool to beginimpacting shortly after the tip of the lag screw is driven into theworkpiece. As lag screws can be relatively long, a significant amount oftime can be expended in driving lag screws into workpieces.

Hybrid impact tools permit a user to operate the tool in a rotary impactmode or a drill mode that provides continuous rotation of an outputspindle. The ability to change between a rotary impacting mode and anon-impacting mode is highly advantageous as the non-impacting mode ismuch better suited for most types of drilling, particularly whenrelatively small diameter drill bits are employed. While several of theknown hybrid impact tools are generally suited for their intendedpurpose, it will be appreciated that hybrid impact tools are susceptibleto improvement. Such improvements can be made for example, to thetransmission that transmits rotary power from a motor to an inputspindle of the impact mechanism.

SUMMARY

This section provides a general summary of some aspects of the presentdisclosure and is not a comprehensive listing or detailing of either thefull scope of the disclosure or all of the features described therein.

In one form, the present teachings provide a power tool that includes ahousing, a motor, a planetary transmission, a first bearing and a secondbearing. The motor is disposed in the housing and includes an outputshaft. The planetary transmission has a sun gear, a plurality of firstplanet gears, a first ring gear and a carrier. The sun gear is driven bythe output shaft. The first planet gears are driven by the sun gear andhave teeth that are meshingly engaged to teeth of the first ring gear.The carrier includes a rear carrier plate and a front carrier platebetween which the first and second planet gears are received. The rearcarrier plate includes a first bearing aperture. The first bearing isreceived in the first bearing aperture and is configured to support theoutput shaft. The second bearing is received onto the rear carrier plateto support the carrier relative to the housing.

In another form, the present teachings provide a power tool thatincludes a housing, a motor, an output member, a power transmittingmechanism, and a shift mechanism. The motor is coupled to the housingand has an output shaft. The power transmitting mechanism drivinglycouples the output shaft to the output member and includes atransmission having dual planetary stage with a sun gear, a first planetgear, a second planet gear, a planet carrier, a first ring gear and asecond ring gear. The first and second planet gears are rotatablymounted on the planet carrier. The first planet gear is disposed betweenthe motor and the second planet gear and has a pitch diameter that issmaller that a pitch diameter of the second planet gear. The first ringgear is meshingly engaged with the first planet gear and the second ringgear is meshingly engaged with the second planet gear. The shiftmechanism has a collar that is non-rotatably but axially slidablycoupled to the housing for movement between a first position and asecond position. The collar includes an annular collar body, a first setof external splines and a second set of external splines. The collarbody is received about the first ring gear. The first set of externalsplines extend radially inwardly from the collar body and engage a thirdset of external splines formed about the first ring gear when the collaris in the first position to inhibit rotation of the first ring gearrelative to the housing. The second set of external splines is coupledto an end of the collar body that faces opposite the motor. The secondset of external splines engages a fourth set of external splines formedon the second ring gear when the collar is in the second position toinhibit rotation of the second ring gear relative to the housing.

In still another form, the present teachings provide a power tool thatincludes a housing, a motor, an output member, a power transmittingmechanism and a shift mechanism. The motor is coupled to the housing andhas an output shaft. The power transmitting mechanism drivingly couplesthe output shaft to the output member and includes a transmission havingdual planetary stage with a sun gear, a compound planet gear, a planetcarrier, a first ring gear and a second ring gear. The compound planetgear is rotatably mounted on the planet carrier and has first and secondplanet gears that are fixedly coupled to one another. The first planetgear is disposed between the motor and the second planet gear and has apitch diameter that is smaller that a pitch diameter of the secondplanet gear. The first ring gear is meshingly engaged with the firstplanet gear, and the second ring gear being meshingly engaged with thesecond planet gear. The first planet gear has a first quantity (Q1) ofteeth, the second planet gear has second quantity of teeth (Q2) and thequotient of the quantity of teeth on the second planet gear divided bythe quantity of teeth on the first planet (Q2/Q1) gear is not aninteger. The shift mechanism has a collar that is non-rotatably butaxially slidably coupled to the housing for movement between a firstposition and a second position. The collar non-rotatably couples thefirst ring gear to the housing in the first position and non-rotatablycouples the second ring gear to the housing in the second position.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples in this summary are intended for purposes ofillustration only and are not intended to limit the scope of the presentdisclosure, its application and/or uses in any way.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only and arenot intended to limit the scope of the present disclosure in any way.The drawings are illustrative of selected teachings of the presentdisclosure and do not illustrate all possible implementations. Similaror identical elements are given consistent identifying numeralsthroughout the various figures.

FIG. 1 is a perspective view of a hybrid impact tool constructed inaccordance with the teachings of the present disclosure;

FIG. 2 is a perspective, partly broken away view of the hybrid impacttool of FIG. 1;

FIG. 3 is a perspective partly broken away view of the hybrid impacttool of FIG. 1 illustrating the motor assembly and the transmissionassembly in more detail;

FIG. 4 is a longitudinal cross-section view of the portion of the hybridimpact tool illustrated in FIG. 3;

FIG. 5 is a perspective view of a portion of the transmission assemblyillustrating the second ring gear in more detail;

FIG. 6 is a perspective view of the transmission assembly;

FIGS. 7, 8 and 9 are side elevation views of the transmission assemblywith the reduction gearset being configured in high, low and neutralspeed settings, respectively;

FIG. 10 is a schematic illustration of an alternatively constructedreduction gearset;

FIGS. 11 and 12 are schematic illustrations that illustrate alternativeconfigurations that may be employed in the reduction gearset of FIG. 10;

FIG. 13 is a rear elevation view of the planet gears of the reductiongearset of FIG. 3;

FIG. 14 is a view similar to that of FIG. 13 but illustrating analternatively configured planet gears;

FIG. 15 is a perspective partly broken away view illustrating theassembly of the alternatively configured planet gears of FIG. 14 intothe reduction gearset;

FIG. 16 is a perspective view illustrating the assembly of thealternatively configured planet gears of FIG. 14 into the reductiongearset;

FIGS. 17-22 are schematic illustrations that depict alternativelyconfigured switch mechanisms for translating an axially movable member,such as the collar of the transmission assembly;

FIG. 23 is a schematic illustration of another transmission assemblyconstructed in accordance with the teachings of the present disclosure;

FIG. 24 is a plot illustrating the rotational speed of the output of thehybrid impact tool of FIG. 1 as a function its output torque operatingat two different speed settings and using two different motor controlschemes;

FIG. 25 is a perspective, partly broken away view of another hybridimpact tool constructed in accordance with the teachings of the presentdisclosure;

FIG. 26 is a top plan, partly broken away view of the hybrid impact toolof FIG. 25 as set in drill mode that operates a reduction gearset at afirst speed ratio; and

FIG. 27 is a top plan, partly broken away view of the hybrid impact toolof FIG. 25 as set in an impact mode that operates a reduction gearset ata second speed ratio.

DETAILED DESCRIPTION OF THE VARIOUS EMBODIMENTS

With reference to FIGS. 1 through 3, a hybrid impact tool constructed inaccordance with the teachings of the present disclosure is generallyindicated by reference numeral 8. Those of ordinary skill in the artwill appreciate that the hybrid impact tool 8 may be either a corded orcordless (i.e., battery powered) device and that the teachings of thepresent disclosure may have applicability to other types of power tools,including without limitation screwdrivers, drill/drivers,hammer-drill/drivers, rotary hammers and impact drivers. The hybridimpact tool can include a housing 10, a motor assembly 12, a multi-speedtransmission assembly 14, an impact mechanism 16, an output spindle 18,a mode change mechanism 20, a chuck 22, a trigger assembly 24 and abattery pack 26. The chuck 22, the trigger assembly 24 and the batterypack 26 can be conventional in their construction and operation and assuch, will not be discussed in significant detail herein. The impactmechanism 16, output spindle 18 and mode change mechanism 20 can beconstructed as described in co-pending U.S. Provisional PatentApplication No. 61/100,091 entitled “Hybrid Impact Tool”, the entiredisclosure of which is hereby incorporated by reference as if set forthherein in its entirety.

The housing 10 can include a pair of mating housing shells 30 and a gearcase 32 that can be removably coupled to the housing shells 30. Thehousing shells 30 can cooperate to define a handle portion 36 and a bodyportion 38. The handle portion 36 can include a battery pack mount 40,to which the battery pack 26 may be removably mounted, and a switchmount 42 (FIG. 3). The trigger assembly 24 can include a trigger 50 foroperating the hybrid impact tool 8 and a trigger controller 52 (FIG. 3),which can include a switch 54 (FIG. 3) that can be employed toelectrically couple the motor assembly 12 to a power source, such as thebattery pack 26, to operate the hybrid impact tool 8.

With reference to FIGS. 3 and 4, the body portion 38 can define a motorcavity 58, which can be configured to receive the motor assembly 12, arear bearing mount 60 and a front bearing mount 62. The gear case 32 canbe a container-shaped structure that can be fixedly but removablycoupled to the housing shells 30 to house the multi-speed transmissionassembly 14, the impact mechanism 16, the output spindle 18 and the modechange mechanism 20.

The motor assembly 12 can include a motor 70 that can include an outputshaft 72 having a rear end 74 and a forward end 76. The rear end 74 canbe supported for rotation relative to the housing by a bearing 78 thatcan be received in the rear mount 60. The motor 70 can be electricallycoupled to the trigger assembly 24 and the battery pack 26 (FIG. 1) in aconventional manner. It will be appreciated that while the presentdisclosure describes the motor assembly 12 as including anelectrically-powered motor, those of skill in the art will appreciatethat the motor 70 can be any type of motor (e.g., pneumatic, hydraulic,AC electric) for providing rotary power to the multi-speed transmissionassembly 14.

With reference to FIGS. 3, 4 and 6, the multi-speed transmissionassembly 14 can include a reduction gearset 100 and a speed selector102. The reduction gearset 100 can be a single stage, two-speed gearsetbut those of skill in the art will appreciate that the reduction gearset100 could be constructed with more stages depending on a desired gearreduction ratio.

The reduction gearset 100 can include an input sun gear 110, a first setof input planet gears 112, a second set of input planet gears 114, aninput carrier 116, a first input ring gear 118 and a second input ringgear 120. The input sun gear 110 can be coupled for rotation with theoutput shaft 72 of the motor 70. The first set of input planet gears 112can comprise a plurality of first planet gears having a first quantityof teeth that can be arranged about a first pitch diameter, while thesecond set of input planet gears 114 can comprise a plurality of secondplanet gears having a second quantity of teeth that can be arrangedabout a second pitch diameter. The first input ring gear 118 can be anannular structure having a plurality of internal teeth 126 disposedproximate a forward axial face and a plurality of external splines orteeth 128 that can extend radially outwardly from a portion of the firstinput ring gear 118 proximate a rear axial face. The plurality ofinternal teeth 126 can be meshingly engaged with the teeth of the firstplanet gears of the first set of planet gears 112. The second input ringgear 120 can include a plurality of internal teeth 130, which can bemeshingly engaged with the teeth of the second planet gears of thesecond set of planet gears 114, and a plurality of external splines orteeth 132 (FIG. 5) that can extend rearwardly from a rear axial face 134(FIG. 5) of a body 136 (FIG. 5) of the second input ring gear 120. Theinput carrier 116 can include a rear carrier plate 140, a front carrierplate 142 and a plurality of pins (not specifically shown) that can befixedly coupled to the rear and front carrier plates 140 and 142. Theplanet gears of the first and second sets of input planet gears 112 and114 can be rotatably mounted on respective pins. An input spindle 150 ofthe impact mechanism 16 can be coupled for rotation with the frontcarrier plate 142.

With specific reference to FIG. 4, the rear carrier plate 140 can be anannular structure that can be received over the output shaft 72 of themotor 70. The rear carrier plate 140 can include a first portion 160 anda second portion 162. The first portion 160 can be abutted against arear surface of the planet gears of the first set of planet gears 112 toinhibit undesired axial movement of the first and second sets of planetgears 112 and 114. The second portion 162 can be relatively smaller indiameter than the first portion 160 and can be configured to have afirst bearing aperture 161 to receive therein a front motor bearing (orfirst bearing) 166 that can support the output shaft 72. An impactmechanism support bearing (or second bearing) 168 can be received overthe second portion 162 of the rear carrier plate 140 and can be engagedto a bearing support plate 170 that is received in the housing 10 anddisposed between the motor 70 and the reduction gearset 100.Configuration in this manner nests the front motor bearing 166 and theimpact mechanism support bearing 168 to reduce the overall length of thetool, as well as aids in the alignment of the motor 70 and the impactmechanism 16 (FIG. 3) as the front motor bearing 166 and the impactmechanism support bearing 168 are mounted on the same machined piece(i.e., the rear carrier plate 140).

In the particular example provided, the planet gears of the first set ofplanet gears 112 are axially offset from the motor 70 by a distance thatis smaller than the amount by which the planet gears of the second setof planet gears 114 are axially offset from the motor 70 (i.e., theplanet gears of the first set of planet gears 112 are closer to themotor 70 than the planet gears of the second set of planet gears 114);the second quantity of teeth is greater than the first quantity ofteeth; the second pitch diameter is larger than the first pitchdiameter; each of the planet gears of the first set of planet gears 112is coupled for rotation with a corresponding one of the planet gears ofthe second set of planet gears 114 (e.g., the planet gears of the firstand second sets of planet gears 112 and 114 can be integrally formed);and only the planet gears of the second set of input planet gears 114are meshingly engaged with the input sun gear 110 (FIG. 3). It will beappreciated that rotation of the input sun gear 110 (FIG. 3) can causecorresponding rotation of the planet gears of the second set of inputplanet gears 114 and that as the planet gears of the first set of inputplanet gears 112 are coupled for rotation with the planet gears of thesecond set of input planet gears 114, the planet gears of the first setof input planet gears 112 may be driven (e.g., by the input sun gear110) without directly engaging an associated sun gear (not shown).

In FIG. 6, the speed selector 102 can include a switch assembly 200 andan actuator assembly 202. The switch assembly 200 can include a switch210 and a pair of first detent members (not specifically shown), whilethe actuator assembly 202 can include a rail 220, a collar 222, a firstbiasing spring 224 and a second biasing spring 226.

The switch 210 can include a plate structure 230, a switch member 232, apair of second detent members (not specifically shown) and a bushing236. The plate structure 230 can be received in a pair of slots (notspecifically shown) formed into the housing shells 30 (FIG. 1) generallyparallel to the longitudinal axis 240 of the reduction gearset 100. Theswitch member 232 can be configured to receive a manual input from anoperator of the hybrid impact tool 8 (FIG. 1) to move the switch 210between a first switch position and a second switch position. Indicia(not specifically shown) may be marked or formed on one or both of thehousing shells 30 (FIG. 1) or the plate structure 230 to indicate aposition into which the switch 210 is located. The second detent memberscan cooperate with the first detent members to resist movement of theswitch 210. In the example provided, the second detent members comprisea plurality of detent recesses that are formed in the plate structure230. The bushing 236 can be coupled to a lateral side of the platestructure 230 and can include a bushing aperture (not specificallyshown) and first and second end faces 244 and 246, respectively.

Each of the housing shells 30 (FIG. 1) can define a pair of detentmounts (not specifically shown) that can be configured to hold the firstdetent members. The first detent members can be leaf springs that can beconfigured to engage the detent recesses that are formed in the platestructure 230 to resist movement of the switch 210 relative to thehousing shells 30 (FIG. 1).

The rail 220 can include a generally cylindrical rail body 250 and ahead portion 252 that can be relatively large in diameter than the railbody 250. The rail 220 can be received through the bushing aperture inthe bushing 236 such that the bushing 236 is slidably mounted on therail body 250.

With additional reference to FIG. 3, the collar 222 can be an annularstructure that can include a mount 260, a plurality of internal splinesor teeth 262 formed about the inside surface of the collar 222, and aplurality of teeth 264 formed into the front axial face of the collar222. An end of the rail body 250 opposite the head portion 252 can bereceived into the mount 260 to fixedly couple the rail 220 to the collar222. In the particular example provided, the rail body 220 is press-fitinto the mount 260, but it will be appreciated that other couplingtechniques, including bonding, adhesives, pins and threaded fasteners,could be employed to couple the rail 220 to the collar 222. The internalsplines or teeth 262 formed about the inside surface of the collar 222can be sized to engage the external splines or teeth 128 formed on thefirst input ring gear 118, while the plurality of or teeth 264 formedinto the front axial face of the collar 222 can be sized to engage theexternal splines or teeth 132 that extend rearwardly from the rear axialface 134 of the body 136 of the second input ring gear 120. Lugs 270formed on the collar 222 can be slidably received in axially extendinggrooves (not specifically shown) formed in the gear case 32 (FIG. 1) toaid in guiding the collar 222.

The first biasing spring 224 can be mounted on the rail body 250 betweenthe head portion 252 and the first end face 244 of the bushing 236. Thesecond biasing spring 226 can be mounted on the rail body 250 betweenthe second end face 246 of the bushing 236 and the collar 222.

With reference to FIGS. 7-9, the collar 222, the first input ring gear118 and the second input ring gear 120 are shown relative to thelongitudinal axis 240 of the reduction gearset 100. It will beappreciated that the collar 222 can be moved axially along thelongitudinal axis 240 between a first position (FIG. 7) and a secondposition (FIG. 8).

In the first position, which is illustrated in FIG. 7, the internalsplines or teeth 262 (best shown in FIG. 3) formed about the insidesurface of the collar 222 can be meshingly engaged with the externalsplines or teeth 128 (best shown in FIG. 3) of the first input ring gear118 while the internal splines or teeth 264 formed on the collar 222 aredisengaged from the external splines or teeth 132 formed on the secondinput ring gear 120. Positioning of the collar 222 in this mannerpermits the reduction gearset 100 to operate at a first gear ratio. Morespecifically and with additional reference to FIG. 3, rotary powerreceived from the motor 70 is transmitted through the input sun gear 110to cause the planet gears of the second set of input planet gears 114 torotate about the pins of the input carrier 116. As the planet gears ofthe first set of input planet gears 112 are coupled for rotation withthe planet gears of the second set of input planet gears 114, the planetgears of the first set of input planet gears 112 will rotate about thepins of the input carrier 116. Since the first input ring gear 118 isnon-rotatably coupled to the gear case 32 (FIG. 4) via the collar 222,rotation of the planet gears of the first set of input planet gears 112causes rotation of the input carrier 116 at a speed that is determinedin part based on the first gear ratio. It will be appreciated that asthe collar 222 is not engaged to the second input ring gear 120,rotation of the planet gears of the second set of input planet gears 114will cause rotation of the second input ring gear 120.

In the second position, which is illustrated in FIG. 8, the internalsplines or teeth 262 (best shown in FIG. 3) formed about the insidesurface of the collar 222 can be disengaged from the external splines orteeth 128 (best shown in FIG. 3) of the first input ring gear 118 whilethe internal splines or teeth 264 formed on the collar 222 can beengaged to the external splines or teeth 132 (best shown in FIG. 5.)formed on the second input ring gear 120. Positioning of the collar 222in this manner permits the reduction gearset 100 to operate at a secondgear ratio. More specifically and with additional reference to FIG. 3,rotary power received from the motor 70 is transmitted through the inputsun gear 110 to cause the planet gears of the second set of input planetgears 114 to rotate about the pins of the input carrier 116. Since thesecond input ring gear 120 is non-rotatably coupled to the gear case 32(FIG. 4) via the collar 222, rotation of the planet gears of the secondset of input planet gears 114 causes rotation of the input carrier 116at a speed that is determined in part based on the second gear ratio. Itwill be appreciated that as the collar 222 is not engaged to the firstinput ring gear 118, rotation of the planet gears of the second set ofinput planet gears 114 will cause rotation of the first input ring gear118 (via corresponding rotation of the planet gears of the first set ofinput planet gears 112).

Configuration of the reduction gearset 100 and collar 222 in the mannerprovides several advantages. For example, the above-describedconfiguration permits the collar 222 to be shifted into a neutralposition when being moved between the first and second positions (i.e.,the collar 222 will fully disengage the first input ring gear 118 beforeinitiating engagement with the second input ring gear 120 and viceversa) as is shown in FIG. 9. With reference to FIGS. 3, 4 and 6, thecombination of the axial spacing apart of the internal splines or teeth126 and the external splines or teeth 128 of the first input ring gear118 provides additional room for shifting the collar 222 whileefficiently packaging the front motor bearing 166 and the impactmechanism support bearing 168 in a way that provides the desired neutralposition in addition to a reduction in the overall length of the hybridimpact tool 8 (FIG. 1). Stated another way, the “additional” lengthneeded to provide a neutral position is obtained by positioning theexternal splines or teeth 128 of the first input ring gear 118 furtherrearwardly than they otherwise would have been, so that the externalsplines or teeth 128 are located in a position or axial zone that isemployed to house the bearings 166 and 168 that support the motor 70 andthe impact mechanism 16 permits the overall length of the hybrid impacttool 8 (FIG. 1) to be reduced.

As another example, the above-described configuration utilizes splinesor teeth on the rear and front faces of the second input ring gear 120and the collar 222, respectively, to reduce the overall diameter of thereduction gearset 100 as compared with an arrangement that places themating splines or teeth on the second input ring gear 120 and the collar222 in a radial orientation (as with the first input ring gear 118 andthe collar 222). It will be apparent to those of skill in the art thatas the planet gears of the first set of planet gears 112 are disposedabout a smaller pitch diameter in the example provided, the first inputring gear 118 can be relatively smaller in diameter than the secondinput ring gear 120 and consequently, the use of mating splines or teethdisposed in a radial direction do not have a similar impact on theoverall diameter of the reduction gearset 100.

It will be appreciated that the first and second biasing springs 224 and226 are configured to resiliently couple the collar 222 to the switch210 in a manner that provides for a modicum of compliance. In instanceswhere the switch 210 is to be moved from the first switch position tothe second switch position but the internal splines or teeth 264 formedon the collar 222 are not aligned to the external splines or teeth 132formed on the second input ring gear 120, the switch 210 can betranslated into the second switch position without fully moving thecollar 222 by an accompanying amount. In such situations, the secondbiasing spring 226 is compressed between the second end face 246 of thebushing 236 and the mount 260 of the collar 222. Rotation of the secondinput ring gear 120 relative to the collar 222 can permit the externalsplines or teeth 132 formed on the second input ring gear 120 to alignto the internal splines or teeth 264 formed on the collar 222 and oncealigned, the second biasing spring 226 can urge the collar 222 forwardlyinto engagement with the second input ring gear 120.

In instances where the switch 210 is to be moved from the second switchposition to the first switch position but the internal splines or teeth262 formed about the inside surface of the collar 222 are not aligned tothe external splines or teeth 128 of the first input ring gear 118, theswitch 210 can be translated into the first switch position withoutfully moving the collar 222 by an accompanying amount. In suchsituations, the first biasing spring 224 is compressed between the headportion 252 of the rail 220 and the first end face 244 of the bushing236. Rotation of the first input ring gear 118 relative to the collar222 can permit the external splines or teeth 128 to align to theinternal splines or teeth 262 formed about the collar 222 and oncealigned, the first biasing spring 224 can urge the collar 222 rearwardlyinto engagement with the first input ring gear 118.

It will be appreciated that the motor bearing 166 may be positionedsomewhat differently from that which is described above as is shown inFIGS. 10, 11 and 12. In the example of FIG. 10 the reduction gearset100′ includes a fixed input stage 300 and a fixed output stage 302(i.e., the input and output stages 300 and 302 always providecorresponding gear reductions). The motor output shaft 72′ is receivedthrough an input carrier 304 associated with the input stage 300 and themotor bearing 166′ is received in an output carrier/spindle 308associated with the output stage 302. The impact mechanism bearing 168′is mounted on the output carrier 308. The example of FIG. 11 partlyillustrates a similar motor output shaft 72′″ except that the portion312 of the motor output shaft 72″ between the input sun gear 110″ andthe motor bearing 166″ is necked down in diameter. The example of FIG.12 is similar to the previous example except that the motor output shaft72′″ is received into an end of the input sun gear 110′″ and the motorbearing 166′″ is received onto an opposite end of the input sun gear110′″.

With reference to FIGS. 3 and 13, the reduction gearset 100 can beconfigured such that the quotient of the quantity of teeth 400 on theplanet gears 402 of the second set of input planet gears 114 divided bythe quantity of teeth 406 on the planet gears 408 of the first set ofinput planet gears 112 is an integer. As is well understood by those ofordinary skill in the art, configuration of the first and second sets ofplanet gears 112 and 114 in this manner eliminates the need to time theplanet gears 402, 408 relative to another gear in the reduction gearset100. It will also be appreciated by those of skill in the art thatmaintaining such a relationship between the teeth 400, 406 of the planetgears 402, 408 can limit reduce the number of gear ratios that may beemployed in the design of the reduction gearset 100 and that by changingthe number of teeth 406 on the planet gear 408 relative to the number ofthe teeth 400 on the planet gear 402, a wider selection of gear ratiosis available to the designer while keeping the planet gear 408 coupledfor rotation with the planet gear 402. In situations where the quotientof the quantity of teeth 400′ on the planet gears 402′ of the second setof input planet gears 114′ divided by the quantity of teeth 406′ on theplanet gears 408′ of the first set of input planet gears 112′ is not aninteger, as in the example of FIG. 14, it may be necessary to time theplanet gears 402′, 408′ to be sure that they will properly mesh with theassociated gears of the gearset. To aid in the timing of the gears, atiming aperture 420 is formed in the planet gear 402′ at a desiredlocation. In the particular example provided, the desired location isin-line with teeth 400a′ and 406a′ so that a line extending from thecenter of the gear 402′ can bisect the teeth 402a′, 406a′ and the timingaperture 420.

With reference to FIGS. 15 and 16, a fixture 450 is configured with aplurality of pins 452 for aligning the gears 402′, 408′ relative to theremainder of the gearset. The gears 402′ and 408′ are initiallyassembled to the planet carrier 116 (FIG. 3) and the pins 452 of thefixture 450 are inserted into the timing apertures 420 in the gears402′. The first input ring gear 118 is meshed with the gears 408′ andthe fixture 450 can be removed. The second input ring gear 120 can bemeshed with the planet gears 402′.

While the speed selector 102 (FIG. 6) has been illustrated and describedas including an actuator assembly 202 (FIG. 6) with a rail 220 (FIG. 6),a first biasing spring 224 (FIG. 6) and a second biasing spring 226(FIG. 6), it will be appreciated that the speed selector may beconfigured somewhat differently. For example, the speed selector 102′ ofFIGS. 17 and 18 includes a switch assembly 200′ and an actuator assembly202′. The switch assembly 200′ can include a rotary knob 500 that canextend through the housing 10′, whereas the actuator assembly 202′ caninclude a first portion 510, which can be coupled for rotation with therotary knob 500, and a second portion 512 that can be fixedly coupled tothe collar 222′. The first portion 510 can include a first magnet 514having a north pole N and a south pole 5, while the second portion 512can include a second magnet 516 having a north pole N and a south poleS. It will be appreciated that the collar 222′ is non-rotatably butaxially slidably coupled to another structure, such as a pair of rods(not shown) that can be fixedly coupled to the housing 10′. Rotation ofthe rotary knob 500 into a first rotary position (FIG. 17) can orient apole of the first magnet 514 to an opposite pole on the second magnet516 (e.g., south pole S to north pole N, respectively) so as to causethe second magnet 516 (and the collar 222′ with it) to be drawn towardthe first portion to thereby shift the collar 222′ into the firstposition. Similarly, rotation of the rotary knob 500 into a secondrotary position (FIG. 18) can orient like poles of the first and secondmagnets 514 and 516 (e.g., north poles N and N) toward one another so asto cause the second magnet 516 (and the collar 222′ with it) to be urgedaway from the first portion to thereby shift the collar 222′ into thesecond position. As shown in FIG. 20, a slug 520 formed of amagnetically susceptible material, such as steel, can be coupled to thehousing 10″ to aid in maintaining the rotary knob 500 in the first andsecond rotary positions due to magnetic attraction between the slug 520and the first magnet 514. So in comparison to the speed selector 102,and similar selectors known in the art, this design provides, anactuating force, shift compliance and dententing without the use ofsprings, cams or slots.

The example of FIG. 19 employs a slidable switch 210′ having a rack 530formed thereon, and an actuator assembly 202″ having a pinion 532 thatmeshingly engages the rack 530 and into which the first magnet 514 isdisposed. Sliding of the slidable switch 210′ can orient the north andsouth poles N and S of the first magnet 514 to attract or repel thesecond magnet 516 as desired.

The example of FIG. 21 is similar to that of FIGS. 17 and 18, exceptthat the rotary knob 500′ is disposed between two axially movablecollars 222a and 222b into each of which is disposed one of the secondmagnets 516. In this example, multiple magnets 514a, 514b, 514c, 514dare employed, but it will be appreciated that the quantity andorientation of the first magnets 514 and the orientation of the secondmagnets 516 can be configured to provide a desired movement scheme. Theexample of FIG. 22 is similar to the example of FIG. 19 except that apair of racks 530′ are formed on the sides of the slidable switch 210″,a pair of pinions 532′ are engaged to the racks 530′ and the firstmagnets 514 are disposed vertically below the pinions 532′.

With reference to FIG. 23, a two-speed compound planetary transmission600 is illustrated. The transmission 600 include a sun gear 602, aplurality of first planet gears 604, which are meshingly engaged to thesun gear 602, a plurality of second planet gears 606, which are fixedfor rotation with corresponding ones of the first planet gears 604, afirst ring gear 608, which is meshingly engaged with the first planetgears 604, a second ring gear 610, which is meshingly engaged with thesecond planet gears 606, a planet carrier 612, which has pins 614 ontowhich the first and second planet gears 604 and 606 are rotatablyreceived, a shifting collar 616 and an output spindle 618. The shiftingcollar 616 has a plurality of internal teeth 620 and a plurality ofexternal teeth 622. The second ring gear 610 can include a radiallyinwardly extending wall 630 and a plurality of teeth 632 that can becoupled to the wall 630. The planet carrier 612 can include a pluralityof teeth 640. The shifting collar 616 can be splined to the outputspindle 618 to permit the shifting collar 616 to be coupled for rotationwith the output spindle 618 but permit the shifting collar 616 to bemoved axially relative to the output spindle 618.

With regard to the upper half of FIG. 23, the transmission 600 may beoperated in a first speed ratio in which a collar 650 couples the firstring gear 608 to a structure, such as a housing 652, to inhibit rotationof the first ring gear 608 relative to the housing 652. Simultaneously,the shifting collar 616 can be moved into a position in which the teeth622 of the shifting collar 616 are engaged to the teeth 632 of thesecond ring gear 610. The sun gear 602, first planet gears 604 and firstring gear 608 cooperate to cause the second planet gears 606 to rotateat a first rate, which drives the second ring gear 610 and in turn,drives the shifting collar 616 to cause the transmission 600 to operatein a low speed ratio.

With regard to the lower half of FIG. 23, the transmission 600 may beoperated in a second speed ratio in which the collar 650 couples thesecond ring gear 610 to the housing 652 to inhibit rotation of thesecond ring gear 610 relative to the housing 652. Simultaneously, theshifting collar 616 can be moved into a position in which the teeth 620of the shifting collar 616 are engaged to the teeth 640 of the planetcarrier 612, while the teeth 622 are disengaged from the teeth 632. Thesun gear 602, first planet gears 604, second planet gears 606 and secondring gear 610 cooperate to cause the planet carrier 612 to rotate at asecond rate, which drives the shifting collar 616 to cause thetransmission 600 to operate in a high speed ratio.

With reference to FIG. 24, a plot illustrating a relationship betweenthe torque and rotational speed of the output of the hybrid impact tool8 (FIG. 1). It will be appreciated that the trigger controller 52 (FIG.3) can be equipped with circuitry for controlling the distribution ofelectrical power to the motor 70 (FIG. 3) according to two or moreschemes and that the hybrid impact tool 8 (FIG. 1) can be instrumentedto permit a user to select a desired scheme. For example, each of theschemes can be employed to select a duty cycle of the electrical powerthat is provided to the motor 70 (FIG. 3) via a pulse-width modulationtechnique. A first duty cycle having a relatively large ratio of on-timerelative to the total time of the duty cycle can be employed to rotatethe output of the hybrid impact tool 8 (FIG. 1) at a relatively highspeed, and a second duty cycle having a relatively smaller ratio ofon-time relative to the total time of the duty cycle can be employed torotate the output of the hybrid impact tool 8 (FIG. 1) at a relativelylower speed. Combining electronic speed control with the multi-speedcapabilities of the reduction gearset 100 (FIG. 3) can provide thehybrid impact tool 8 (FIG. 1) with four (or more) distinct rotationalspeeds that may be selected as desired to complete various tasks. Itwill be understood that various different types of motors may be bettersuited to different types of control techniques. In some situations, abrushless DC motor, such as an IMP type brushless DC motor, may beemployed for the motor 70 (FIG. 3) to provide enhanced motor control.

With reference to FIGS. 25-27, another hybrid impact tool constructed inaccordance with the teachings of the present disclosure is indicated byreference numeral 8-1. The hybrid impact tool 8-1 can be identical tothe hybrid impact tool 8 of FIG. 1 except as described herein. Morespecifically, the speed selector 102-1 includes a plate structure 230-1that is coupled to the shift cam 5010-1 of the mode change mechanism20-1. The plate structure 230-1 can define a pair of bushings 236-1 and236-2, which can be slidably mounted on a rail 220-1 and a biasingspring 224-1 can be received between the bushings 236-1 and 236-2 andfixed to the rail 220-1 at a predetermined location (such as at amid-point of the stroke of the plate structure 230-1). Pivoting movementof the shift cam 5010-1 is employed to cause corresponding movement of ashaft 5002-1 to move a shift fork 5000-1 and a mode collar 604-1 as isdescribed in the above-referenced Provisional patent application.Briefly, the shift fork 5000-1 can be moved between a first position toengage mode collar 604-1 to both the input spindle 550-1 (FIG. 27) ofthe impact mechanism 16-1 and the hammer 36-1 of the impact mechanism16-1, and a second position to disengage the mode collar 604-1 from thehammer 36-1 of the impact mechanism 16-1. A spring 224-2 can bias theshift fork 5000-1 toward a desired position.

Pivoting movement of the shift cam 5010-1 also causes correspondingsliding motion of the plate structure 230-1 on the rail 220-1 tocompress the biasing spring 224-1 against one of the bushings 236-1 and236-2 depending on the direction in which the shift cam 5010-1 is moved.As the rail 220-1 is fixedly coupled to the collar 222, it will beappreciated that pivoting movement of the shift cam 5010-1 will effect achange in the gear ratio of the reduction gearset 100. It will furtherbe appreciated that the biasing spring 224-1 permits the plate structure230-1 to be moved without a corresponding movement of the collar 222 insituations where the collar 222 is not aligned to either the first ringgear 118 or the second ring gear 120.

It will be appreciated that the above description is merely exemplary innature and is not intended to limit the present disclosure, itsapplication or uses. While specific examples have been described in thespecification and illustrated in the drawings, it will be understood bythose of ordinary skill in the art that various changes may be made andequivalents may be substituted for elements thereof without departingfrom the scope of the present disclosure as defined in the claims.Furthermore, the mixing and matching of features, elements and/orfunctions between various examples is expressly contemplated herein,even if not specifically shown or described, so that one of ordinaryskill in the art would appreciate from this disclosure that features,elements and/or functions of one example may be incorporated intoanother example as appropriate, unless described otherwise, above.Moreover, many modifications may be made to adapt a particular situationor material to the teachings of the present disclosure without departingfrom the essential scope thereof. Therefore, it is intended that thepresent disclosure not be limited to the particular examples illustratedby the drawings and described in the specification as the best modepresently contemplated for carrying out the teachings of the presentdisclosure, but that the scope of the present disclosure will includeany embodiments falling within the foregoing description and theappended claims.

What is claimed is:
 1. A power tool comprising: a housing; a motorcoupled to the housing, the motor having an output shaft; an outputmember; a power transmitting mechanism drivingly coupling the outputshaft to the output member, the mechanism comprising a transmissionhaving dual planetary stage with a sun gear, a first planet gear, asecond planet gear, a planet carrier, a first ring gear and a secondring gear, the first and second planet gears being rotatably mounted onthe planet carrier, the first planet gear being disposed between themotor and the second planet gear and having a pitch diameter that issmaller than a pitch diameter of the second planet gear, the first ringgear being meshingly engaged with the first planet gear, and the secondring gear being meshingly engaged with the second planet gear; and ashift mechanism having a collar that is non-rotatably but axiallyslidably coupled to the housing for movement between a first positionand a second position, wherein the collar comprises an annular collarbody, a first set of external splines and a second set of externalsplines, the collar body being received about the first ring gear, thefirst set of external splines extending radially inwardly from thecollar body and engaging a third set of external splines formed aboutthe first ring gear when the collar is in the first position to therebyinhibit rotation of the first ring gear relative to the housing, thesecond set of external splines being coupled to an end of the collarbody that faces opposite the motor, the second set of external splinesengaging a fourth set of external splines formed on the second ring gearwhen the collar is in the second position to thereby inhibit rotation ofthe second ring gear relative to the housing.
 2. The power tool of claim1, wherein the power transmitting mechanism comprises a rotary impactmechanism having an input spindle and an anvil, the input spindle beingcoupled for rotation with an output of the transmission, the outputmember being coupled for rotation with the anvil.
 3. The power tool ofclaim 1, wherein the shift mechanism further comprises a switch memberand a pair of springs, the springs cooperating to bias the collar into aneutral position relative to the switch member.
 4. The power tool ofclaim 3, wherein the shift mechanism further comprises a rod that isfixedly coupled to the collar, the switch member being movably mountedon the rod.
 5. The power tool of claim 4, wherein the springs aremounted on the rod on opposite sides of the switch member.
 6. The powertool of claim 1, wherein the first and second planet gears are unitarilyformed.
 7. The power tool of claim 6, wherein the first planet gear hasa first quantity (Q1) of teeth, the second planet gear has secondquantity of teeth (Q2) and wherein the quotient of the quantity of teethon the second planet gear divided by the quantity of teeth on the firstplanet (Q2/Q1) gear is not an integer.
 8. The power tool of claim 7,wherein a timing aperture is formed in at least one of the first andsecond planet gears, the timing aperture being indexed at apredetermined angle relative to a timing tooth on one of the first andsecond planet gears.
 9. A power tool comprising: a housing; a motorcoupled to the housing, the motor having an output shaft; an outputmember; a power transmitting mechanism drivingly coupling the outputshaft to the output member, the mechanism comprising a transmissionhaving dual planetary stage with a sun gear, a compound planet gear, aplanet carrier, a first ring gear and a second ring gear, the compoundplanet gear being rotatably mounted on the planet carrier and havingfirst and second planet gears that are fixedly coupled to and integrallyformed with one another, the first planet gear being disposed betweenthe motor and the second planet gear and having a pitch diameter that issmaller than a pitch diameter of the second planet gear, the first ringgear being meshingly engaged with the first planet gear, and the secondring gear being meshingly engaged with the second planet gear, whereinthe first planet gear has a first quantity (Q1) of teeth, the secondplanet gear has second quantity of teeth (Q2) and wherein the quotientof the quantity of teeth on the second planet gear divided by thequantity of teeth on the first planet (Q2/Q1) gear is not an integer;and a shift mechanism with a collar that is non-rotatably but axiallyslidably coupled to the housing for movement between a first positionand a second position, wherein the collar non-rotatably couples thefirst ring gear to the housing in the first position and non-rotatablycouples the second ring gear to the housing in the second position. 10.The power tool of claim 9, wherein a timing aperture is formed in atleast one of the first and second planet gears, the timing aperturebeing indexed at a predetermined angle relative to a timing tooth on oneof the first and second planet gears.
 11. A power tool comprising: ahousing; a motor in the housing, the motor including an output shaft; aplanetary transmission having a sun gear, a plurality of first planetgears, a first ring gear and a carrier, the sun gear being driven by theoutput shaft, the first planet gears being driven by the sun gear andhaving teeth that are meshingly engaged to teeth of the first ring gear,the carrier including a rear carrier plate and a front carrier platebetween which the first planet gears are received, the rear carrierplate including a first bearing aperture; a first bearing received inthe first bearing aperture and being configured to support the outputshaft; and a second bearing received onto the rear carrier plate tosupport the carrier relative to the housing.
 12. The power tool of claim11, wherein the planetary transmission includes a plurality of secondplanet gears.
 13. The power tool of claim 12, wherein each of the firstplanet gears is coupled for rotation with a corresponding one of thesecond planet gears.
 14. The power tool of claim 13, wherein each of thefirst planet gears has a first pitch diameter and each of the secondplanet gears has a second pitch diameter that is larger than the firstpitch diameter.
 15. The power tool of claim 13, wherein the first ringgear includes a plurality of external teeth that are axially spacedapart from the teeth that are meshingly engaged by the teeth of thefirst planet gears.
 16. The power tool of claim 15, wherein the externalteeth are positioned at least partly vertically in-line with at leastone of the first and second bearings.
 17. The power tool of claim 15,further comprising an axially slidable collar that is movable between afirst position, in which the collar is engaged to the external teeth ofthe first ring gear, and a second position in which the collar isengaged to a second ring gear that is meshingly engaged to the secondplanet gears.
 18. The power tool of claim 17, wherein the collar isnon-rotatably coupled to the housing.
 19. The power tool of claim 18,further comprising a switch member, a first spring (224) and a secondspring, the first spring (224) being compressed when the switch memberis moved from a first switch position to a second switch positionwithout a corresponding movement of the collar from the first positionto the second position, the second spring being compressed when theswitch member is moved from the second switch position to the firstswitch position without a corresponding movement of the collar from thesecond position to the first position.
 20. The power tool of claim 11,wherein the second bearing is engaged to a bearing support plate that isreceived in the housing.
 21. The power tool of claim 11, wherein thesecond bearing is substantially axially aligned with the first bearing.22. The power tool of claim 11, wherein the rear carrier plate comprisesan annular structure with a first portion and a second portion, thefirst portion having a larger diameter than the second portion.
 23. Thepower tool of claim 22, wherein the first portion abuts against a rearsurface of the first planet gears.
 24. The power tool of claim 22,wherein the second portion receives the first bearing therein.
 25. Thepower tool of claim 24, wherein the second bearing is received onto thesecond portion.
 26. The power tool of claim 11, wherein the output shafthas a front end portion supported axially forward of the motor by thefirst bearing and a rear end portion supported axially rearward of themotor by a third bearing received in a rear mount of the housing. 27.The power tool of claim 11, further comprising an output spindleconfigured to be rotationally driven by rotation of the carrier.
 28. Thepower tool of claim 27, further comprising an impact mechanism disposedbetween the carrier and the output spindle, wherein the carrierrotationally drives the output spindle via the impact mechanism.
 29. Thepower tool of claim 28, wherein the impact mechanism has an inputspindle that is coupled for rotation with the front carrier plate. 30.The power tool of claim 27, further comprising a chuck coupled forrotation with the output spindle.
 31. The power tool of claim 11,wherein the sun gear is coupled for rotation with the output shaftaxially forward of the first bearing.
 32. The power tool of claim 11,further comprising a controller configured to control distribution ofelectrical power to the motor.
 33. The power tool of claim 32, whereinthe controller is configured to select between at least a first controlscheme and a second control scheme based on a user input, wherein, inthe first control scheme, the controller causes rotation of the motor ata first rotational speed, and in the second control scheme, thecontroller causes rotation of the motor at a second rotational speedthat is lower than the first rotational speed.
 34. The power tool ofclaim 33, wherein the housing is instrumented to receive the user inputof a selection between the first control scheme and the second controlscheme.
 35. The power tool of claim 33, wherein, in the first controlscheme, electrical power is provided to the motor by apulse-width-modulation signal having a relatively large ratio of on-timerelative to the total time of the duty cycle, and, in the second controlscheme, electrical power is provided to the motor by apulse-width-modulation signal having a relatively smaller ratio ofon-time relative to the total time of the duty cycle.
 36. A power toolcomprising: a housing; a motor in the housing, the motor including anoutput shaft having a forward end portion and a rear end portion; aplanetary transmission having a sun gear, a plurality of planet gears, aring gear and a planet gear carrier, the sun gear being driven inrotation by the output shaft, the plurality of planet gears being drivenin rotation by the sun gear and having teeth that are meshingly engagedto teeth of the ring gear, and the carrier being driven in rotation bymotion of the planet gears, the carrier defining a first bearingaperture; an impact mechanism having an input shaft that is fixedlycoupled for rotation with the carrier and an output spindle; a firstbearing received in the first bearing aperture and being configured tosupport the forward end of the output shaft; and a second bearingreceived onto the carrier to support the carrier relative to thehousing.
 37. The power tool of claim 36, wherein the carrier comprises arear carrier plate axially rearward of the planet gears and a frontcarrier plate axially forward of the planet gears.
 38. The power tool ofclaim 37, wherein the first bearing aperture is defined in the rearcarrier plate axially rearward of the planet gears.
 39. The power toolof claim 36, wherein the second bearing is engaged to a bearing supportplate that is received in the housing.
 40. The power tool of claim 36,wherein the second bearing is substantially axially aligned with thefirst bearing.
 41. The power tool of claim 36, wherein the rear endportion of the motor shaft is supported axially rearward of the motor bya third bearing received in a rear mount of the housing.
 42. The powertool of claim 36, further comprising a controller configured to controldistribution of electrical power to the motor.
 43. The power tool ofclaim 42, wherein the controller is configured to select between atleast a first control scheme and a second control scheme based on a userinput, wherein, in the first control scheme, the controller causesrotation of the motor at a first rotational speed, and in the secondcontrol scheme, the controller causes rotation of the motor at a secondrotational speed that is lower than the first rotational speed.
 44. Thepower tool of claim 43, wherein the housing is instrumented to receivethe user input of a selection between the first control scheme and thesecond control scheme.
 45. The power tool of claim 43, wherein, in thefirst control scheme, electrical power is provided to the motor by apulse-width-modulation signal having a relatively large ratio of on-timerelative to the total time of the duty cycle, and, in the second controlscheme, electrical power is provided to the motor by apulse-width-modulation signal having a relatively smaller ratio ofon-time relative to the total time of the duty cycle.